Hydraulic casing centralizer device, system, and method for expanding the same

ABSTRACT

A hydraulic casing centralizer device includes a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof. The hydraulic casing centralizer device includes a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber. The hydraulic casing centralizer device includes a threaded section that is configured for screwing the device into a casing joint. The threaded section may be disposed in the cylindrical housing.

BACKGROUND

A casing centralizer is a mechanical tool that is used for centering casing with respect to a wellbore wall. Casing centralizers form bumps or protrusions around the casing to completely seal the casing to the wellbore wall. Casing centralizers may be simple with bow-springs that bounce the casing off from the wellbore wall. Bow-springs may be slightly larger than the wellbore to provide in vertical wells. A setback of these simple casing centralizers is that they usually do not support the weight of the casing in deviated wellbores. Casing centralizers may be complex with additional rugged surfaces to improve performance in deviated wellbores. A setback of these complex centralizers is that they are expensive to manufacture and they are usually smaller than some wellbores, which prevents them from providing any centralization capabilities in some well sites.

SUMMARY

In general, in one aspect, embodiments disclosed herein relate to a hydraulic casing centralizer device. The hydraulic casing centralizer device includes a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof. The hydraulic casing centralizer device includes a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber. The hydraulic casing centralizer device includes a threaded section that is configured for screwing the device into a casing joint, the threaded section being disposed in the cylindrical housing.

In general, in one aspect, embodiments disclosed herein relate to a system for expanding a hydraulic casing centralizer device. The system includes a casing joint comprising an upper casing joint and a lower casing joint, the casing joint having a hollowed center that expands through an entire length thereof. The hydraulic casing centralizer device includes a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof. The hydraulic casing centralizer device includes a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber. The hydraulic casing centralizer device includes a threaded section that is configured for screwing the device into the upper casing joint and the lower casing joint, the threaded section being disposed in the cylindrical housing.

In general, in one aspect, embodiments disclosed herein relate to a method for expanding a hydraulic casing centralizer device. The method includes identifying a well for disposing a system for expanding a hydraulic casing centralizer device. The method includes lowering the system into the well. The system includes a casing joint comprising an upper casing joint and a lower casing joint, the casing joint having a hollowed center that expands through an entire length thereof. The hydraulic casing centralizer device includes a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof. The hydraulic casing centralizer device includes a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber. The hydraulic casing centralizer device includes a threaded section that is configured for screwing the device into the upper casing joint and the lower casing joint, the threaded section being disposed in the cylindrical housing.

Other aspects of the disclosure will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

Specific embodiments of the disclosed technology will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.

FIG. 1 shows a schematic diagram showing a hydraulic casing centralizer device in accordance with one or more embodiments.

FIG. 2 shows a schematic diagram showing a hydraulic casing centralizer device in accordance with one or more embodiments.

FIGS. 3A-3C show a schematic diagram showing a hydraulic casing centralizer system in accordance with one or more embodiments.

FIGS. 4A and 4B show a schematic diagram showing a cross-section view of a hydraulic casing centralizer device in accordance with one or more embodiments.

FIG. 5 shows a schematic diagram showing a cross-section view of a hydraulic casing centralizer device in accordance with one or more embodiments.

FIG. 6 shows a schematic diagram showing a cross-section view of a hydraulic casing centralizer device in accordance with one or more embodiments.

FIGS. 7A-7C show a schematic diagram showing a hydraulic casing centralizer system in accordance with one or more embodiments.

FIG. 8 shows a flowchart in accordance with one or more embodiments.

DETAILED DESCRIPTION

Specific embodiments of the disclosure will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency.

In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.

In general, some embodiments of the disclosure include a hydraulic casing centralizer device, a hydraulic casing centralizer system, and a method for expanding the hydraulic casing centralizer device. A hydraulic casing centralizer device may be a casing centralizer that provides dynamic centralization of a casing in a well by providing a locking mechanism that adapts to spacing allowed for expansion. The locking mechanism includes expandable blades that improve standoff of a casing disposed on deviated and horizontal wellbores. The locking mechanism improves standoff of the casing by providing different expanding lengths for each expandable blade based on the space between the hydraulic casing centralizer device and the wellbore wall.

Casing centralizers are essential in drilling operations, as they keep the casing positioned in a center of the wellbore. In some embodiments, the hydraulic casing centralizer system may be installed to the casing in different locations and secured with stop collars to keep them in place, their main function is to minimize casing to wellbore contact. As a result, a continuous annular clearance around the casing allows cement to completely seal the casing to the wellbore.

Advantageously, in one or more embodiments, the hydraulic casing centralizer device provides the stability of a complex casing centralizer with rigid or molded-on fins while maintaining the versatility of a simple casing centralizer with bow-springs. In one or more embodiments, the locking mechanism is not activated until a desired location is obtained for the casing in the well. In some embodiments, the hydraulic casing centralizer device reduces drag forces and eliminates risk of not being able to pass an obstruction in a wellbore that can fit casing but cannot fit a simple casing centralizer. Further, the hydraulic casing centralizer eliminates risk of getting stuck because it has a variable outer diameter. In some embodiments, the hydraulic casing centralizer device improves casing standoff in horizontal sections where collapsible centralizers cannot take a casing load; improves pass-through tight spots, minimizes risk of stuck; and saves rig time and costs in some cases where casing may get stuck or may not pass an obstruction because of centralizer diameter.

FIG. 1 shows a schematic diagram illustrating a hydraulic casing centralizer device 100 in a retracted position. In this position, the hydraulic casing centralizer device 100 may be connected to two threaded sections of a casing joint (not shown) that attach to a cylindrical housing 110 of the hydraulic casing centralizer device 100. In some embodiments, the hydraulic casing centralizer device 100 includes the cylindrical housing 110, locking mechanism 120, and threaded sections 130 on both ends of the cylindrical housing 110. The cylindrical housing 110 may include a central chamber 140 that extends through a portion of a cylindrical housing and a long a central axis 150. The locking mechanism 120 may be made out of a material with high friction (i.e., rubber). The locking mechanism 120 may be flushed to an outer surface of the cylindrical housing 110 in the retracted position. Once the hydraulic casing centralizer device 100 is attached to the casing joint and once the casing joint is disposed in a specific location in a wellbore, the locking mechanism 120 may be expanded to fit a spacing between the cylindrical housing 110 and the wellbore wall (not shown).

FIG. 2 shows a schematic diagram illustrating the hydraulic casing centralizer device 100 in an expanded position. In this position, the locking mechanism 120 of the hydraulic casing centralizer device 100 is expanded to adapt to the spacing between the cylindrical housing 110 and the wellbore wall. In some embodiments, the locking mechanism 120 adheres to the wellbore wall through the high friction surfaces in combination with a pressure applied through hydraulic force from the inside of the central chamber 140. The central chamber 140 may be hollowed out space to match a hollowed out space in the casing joint. The cylindrical housing 110 may be rated to be used in hazardous locations and to withstand the movement of highly corrosive fluids. The locking mechanism 120 may react to the hydraulic force to expand in proportion to the hydraulic force being applied. The locking mechanism 120 may expand in an outward direction from the cylindrical housing 110 as a result.

FIGS. 3A-3C show a schematic diagram illustrating an adapting process for the hydraulic casing centralizer device 100 disposed in a hydraulic casing centralizer system 300. In the hydraulic casing centralizer system 300, the hydraulic casing centralizer device 100 is attached through the threaded sections 130 to the casing joint. The casing joint includes an upper casing joint 310 a and a lower casing joint 310 b. In FIG. 3A, the hydraulic casing centralizer system 300 is shown being lowered into a wellbore 320, which is delimited by a wellbore wall 330. During the installation of the hydraulic casing centralizer system 300, the hydraulic casing centralizer device 100 is expected to help balancing the force in a given casing segment of the casing joint where the hydraulic casing centralizer device 100 is installed. In FIGS. 3A-3C, a casing segment start 350 a and a casing segment end 350 b represent the start and the end of a given casing segment, respectively. In the given casing segment, gravitational force pulls the given casing segment downward while axial tension pushes the casing upward. Depending on a weight of the casing joint, the net force in the given casing segment is upward or downward. This net force may be different for different casing segments at different points of the wellbore 320. In this regard, casing deflection 360 and casing standoff 370 may be calculated by evaluating a well path, a hole size, a casing outer diameter, a casing weight, one or more casing centralizer properties, and the positions and densities of mud and cement slurries in the well. The casing standoff 370 may be a value between 0 percent and 100 percent, representing alignment of the casing joint with the centricity of the wellbore 320.

In FIG. 3B, the casing joint has been lowered in a portion of the well. FIG. 3B illustrates that the casing joint has a low standoff 370 by virtue of a large casing deflection 360 at different points of the given casing segment, when the casing joint has been lowered in a direction represented by arrows 380. In this case, the locking mechanism 120 is in a retracted position which keeps the locking mechanism 120 flushed with the cylindrical housing 110. Once a desired position for the given segment is chosen along the wellbore 320, the locking mechanism 120 may be expanded into an expanded position to push against the wellbore wall 330 to center the casing joint at the given casing segment.

In FIG. 3C, the casing joint is centered by expanding the locking mechanism 120 away from the hydraulic casing centralizer device 100 in a direction of arrows 390, such that the locking mechanism 120 expands against the wellbore wall 330. In this position, the given casing segment is centered by adapting the locking mechanism 120 to the space between the hydraulic casing centralizer device 100 and the wellbore wall 330. In some embodiments, extendable portions of the locking mechanism 120 extend at different lengths based on their respective spacing. The extendable portions extend in proportion to a hydraulic force exerted from inside the central chamber 140.

FIGS. 4A and 4B show a schematic diagram of a cross-section 400 of the hydraulic casing centralizer device 100. The cross-section 400 shows that the locking mechanism 120 includes at least one radially extendible blade 410 that is held in place between two springs 420 a and 420 b located above and below the at least one extendable blade 410, respectively. Further, the at least one radially extendible blade 410 may include a partial length 430 of a total length 435 of the cylindrical housing 110 that allows the at least one radially extendible blade 410 to expand in an outward direction. The partial length 430 being 75% or 50% of the total length 435 of the cylindrical housing 110. The at least one radially extendible blade 410 may be prevented from moving back towards the central chamber 140 using structural fins 440, which allow the at least one radially extendible blade 410 to move outwardly different distances based on a hydraulic force 470 applied from the central chamber 140.

FIG. 5 shows a cross-section view of a half 500 of the hydraulic casing centralizer device 100. The half 500 of the hydraulic casing centralizer device 100 shows the threaded sections 130 along an inner surface of the cylindrical housing 110, which faces the central chamber 140. The half 500 shows three extendable blades 410 a, 410 b, and 410 c held in place by the two springs 420 a and 420 b in combination with the structural fins 440. The three extendable blades 410 a, 410 b, and 410 c allow for three different lengths of expansion to centralize the hydraulic casing centralizer system 300. In some embodiments, the hydraulic casing centralizer device 100 includes a float collar 450 coupled to a ball seat 460. The float collar 450 may be disposed in an upper receiving area of the cylindrical housing 110. The ball seat 460 coupled to the float collar 450 may be configured to receive a ball.

FIG. 6 shows a cross-section view of a half 500 of the hydraulic casing centralizer device 100 holding a pressure ball 610. The pressure ball 610 may be a ball made out of metal or a non-corrosive material. The pressure ball 610 may be dropped onto the given casing segment such that the ball seat 460 may receive the pressure ball 610. Once the pressure ball 610 is received in the ball seat 460, the hydraulic force 470 may be applied through a hollowed center of the casing joint to push the pressure ball 610 against the ball seat 460, through the float collar 450, and into the central chamber 140. As the pressure ball 610 enters into the central chamber 140, the hydraulic force 470 is transferred from an axial direction along the hollowed center and overlapping the central axis 150 to a longitudinal direction orthogonal to a direction of the central axis 150. The hydraulic pressure being transferred depends on a speed at which the pressure ball 610 transitions into the central chamber 140. In this regard, the pressure ball 610 may have a circumference proportional to a circumference of an aperture of the float collar 450.

FIGS. 7A-7C show a process 700 for extending the locking mechanism 120 of the hydraulic casing centralizer device 100 in accordance to one or more embodiments. In these drawings, the given casing segment is shown located at a distance from a bottom 710 of the wellbore 320. In FIG. 7A, the pressure ball 610 may be dropped or pushed along the hollowed space of the upper casing joint 310 a of the casing joint. Once the ball reaches the float collar 450, the pressure ball 610 is further pushed to enter the central chamber 140 to expand the locking mechanism 120 to meet the wellbore wall 330 as shown in FIG. 7B. Finally, as shown in FIG. 7C, upon fully expanding the locking mechanism 120, the pressure ball 610 is pushed past the central chamber 140 and dropped to the bottom 710 of the wellbore 320. The distance from the bottom 710 of the wellbore 320 may be a predetermined location of the well that may have been identified before inserting the casing segment into the wellbore 320.

FIG. 8 shows a flowchart in accordance with one or more embodiments. Specifically, FIG. 8 describes a method for expanding the hydraulic casing centralizer device 100. In some embodiments, the method may be implemented using the hydraulic casing centralizer system 300 as described in reference to FIGS. 3A-3C. While the various blocks in FIG. 8 are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined or omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively.

As noted above, casing centralizers are essential in drilling operations as they keep the casing joint positioned in the center of the wellbore 320. The hydraulic casing centralizer device 100 may be screwed into the casing joint in the field, at a remote well site. This hydraulic casing centralizer device 100 may have the cylindrical housing 110 and the locking mechanism 120 having the at least one extendable blade 410. In order to keep the extendable blades extracted, the hydraulic casing centralizer device 100 may be preloaded in the locking mechanism 120, which includes two springs 420 a and 420 b planted inside the cylindrical housing 110 to hold the at least one radially extendable blade 410 in place. The casing joint in a given well may contain various numbers of blades depending on the job requirement. The hydraulic casing centralizer device 100 may be utilized in vertical, deviated, or horizontal wellbores.

In one or more embodiments, the at least one radially extendable blade 410 is designed to extend until it touches the wellbore 320 wall from all sides, which increases casing standoff evenly across washouts. The hydraulic casing centralizer device 100 solves low percentages of standoff along the casing joint without jeopardizing cement work.

In Block 810, a well for disposing the hydraulic casing centralizer system 300 is identified. The hydraulic casing centralizer system 300 includes the casing joint including the upper casing joint 310 a and the lower casing joint 310 b. The hydraulic casing centralizer system 300 also includes the hydraulic casing centralizer device 100 threaded to the upper casing joint 310 a and the lower casing joint 310 b though threaded sections 130.

In Block 820, the hydraulic casing centralizer system 300 is lowered into the well. The given casing joint segment, which includes the casing joint, is lowered into a predetermined location of the well. As the hydraulic casing centralizer device 100 is flushed to the cylindrical housing 110, the given casing joint segment may naturally be positioned in positions that reduce the standoff percentage.

In Block 830, the pressure ball 610 is dropped onto the ball seat 460 through the hollowed center of the casing joint. The pressure ball 610 stops at the first instance of the ball seat 460 in the casing segment. The pressure ball 610 is received in the ball seat 460 and the float collar 450 when the casing joint reaches the predetermined location of a well.

In Block 840, the pressure ball 610 is pushed against the ball seat 460 and into the central chamber 140. At this point, pressure may be provided to the pressure ball 610 to squeeze into the hydraulic casing centralizer device 100 such that the at least one radially extendable blade 410 may be squeezed radially between two springs 420 a and 420 b planted inside the cylindrical housing 110.

In Block 850, the hydraulic force 470 is caused to extend the locking mechanism 120 in an outward direction from the cylindrical housing 110 onto the wellbore wall 330. The at least one radially extendable blade 410 is extended to reach the wellbore wall 330 to straighten the casing joint.

In Block 860, the at least one radially extendable blade 410 is extended for a length equal to the portion of the cylindrical housing. At this point, the at least one radially extendable blade 410 is extended as far as possible and along the entirety of the length. The length is equal to a portion of an entire height of the cylindrical housing 110.

While FIGS. 1-8 show various configurations of components, other configurations may be used without departing from the scope of the disclosure. For example, various components in FIG. 1-7C may be combined to create a single component. As another example, the functionality performed by a single component may be performed by two or more components.

While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the disclosure as disclosed herein. Accordingly, the scope of the disclosure should be limited only by the attached claims. 

What is claimed is:
 1. A hydraulic casing centralizer device, the device comprising: a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof; a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber; and a threaded section that is configured for screwing the device into a casing joint, the threaded section being disposed in the cylindrical housing.
 2. The device of claim 1, wherein the locking mechanism comprises radially extendible blades embedded in the cylindrical housing.
 3. The device of claim 2, wherein the radially extendible blades extend for a length equal to the portion of the cylindrical housing.
 4. The device of claim 1, the device further comprising: a float collar disposed in an upper receiving area of the cylindrical housing; and a ball seat coupled to the float collar, the ball seat and the float collar being configured to receive a ball that is dropped inside the device.
 5. The device of claim 4, wherein the ball seat and the float collar ball receive the ball when the casing joint reaches a predetermined location of a well.
 6. The device of claim 1, wherein the hydraulic force is a pressure applied to hydraulically extend the radially extendable blades to fit a hole size to improve casing standoff.
 7. The device of claim 6, wherein the locking mechanism longitudinally squeezes the radially extendable blades between two springs planted inside the cylindrical housing to hold the radially extendable blades in place.
 8. A system for expanding a hydraulic casing centralizer device, the system comprising: a casing joint comprising an upper casing joint and a lower casing joint, the casing joint having a hollowed center that expands through an entire length thereof; and the hydraulic casing centralizer device, the device comprising: a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof, a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber, and a threaded section that is configured for screwing the device into the upper casing joint and the lower casing joint, the threaded section being disposed in the cylindrical housing.
 9. The system of claim 8, wherein the locking mechanism comprises radially extendible blades embedded in the cylindrical housing.
 10. The system of claim 9, wherein the radially extendible blades extend for a length equal to the portion of the cylindrical housing.
 11. The system of claim 8, wherein the device further comprises: a float collar disposed in an upper receiving area of the cylindrical housing; and a ball seat coupled to the float collar, the ball seat and the float collar being configured to receive a ball that is dropped inside the device.
 12. The system of claim 11, wherein the ball seat and the float collar ball receive the ball when the casing joint reaches a predetermined location of a well.
 13. The system of claim 8, wherein the hydraulic force is a pressure applied to hydraulically extend the radially extendable blades to fit a hole size to improve casing standoff.
 14. The system of claim 13, wherein the locking mechanism longitudinally squeezes the radially extendable blades between two springs planted inside the cylindrical housing to hold the radially extendable blades in place.
 15. A method for expanding a hydraulic casing centralizer device, the method comprising: identifying a well for disposing a system for expanding a hydraulic casing centralizer device; lowering the system into the well, the system comprising: a casing joint comprising an upper casing joint and a lower casing joint, the casing joint having a hollowed center that expands through an entire length thereof; and the hydraulic casing centralizer device, the device comprising: a cylindrical housing having a central chamber extending through a portion of the cylindrical housing and along a central axis thereof, a locking mechanism that reacts to a hydraulic force when the hydraulic force is applied from an inside of the central chamber, and a threaded section that is configured for screwing the device into the upper casing joint and the lower casing joint, the threaded section being disposed in the cylindrical housing; and causing the hydraulic force that extends the locking mechanism in an outward direction from the cylindrical housing onto the wellbore wall.
 16. The method of claim 15, wherein the locking mechanism comprises radially extendible blades embedded in the cylindrical housing.
 17. The method of claim 16, the method further comprises: extending the radially extendible blades for a length equal to the portion of the cylindrical housing.
 18. The method of claim 15, wherein the device further comprises: a float collar disposed in an upper receiving area of the cylindrical housing; and a ball seat coupled to the float collar, the ball seat and the float collar being configured to receive a ball that is dropped inside the device.
 19. The method of claim 18, the method further comprises: dropping the ball onto the ball seat through the hollowed center; and receiving the ball on the ball seat and the float collar when the casing joint reaches a predetermined location of a well.
 20. The method of claim 19, the method further comprises: pushing the ball against the ball seat and into the central chamber; and longitudinally squeezing the radially extendable blades between two springs planted inside the cylindrical housing to hold the radially extendable blades in place, wherein the hydraulic force is a pressure applied to hydraulically extend the radially extendable blades to fit a hole size to increase casing standoff. 